Mechanically adaptable projectile and method of manufacturing the same

ABSTRACT

A mechanically adaptable projectile includes, in one example embodiment, a projectile body, the body including structure adapted to secure thereto one of multiple projectile components, and multiple projectile components each sized to be releasably secured to the projectile body, each of the multiple projectile components structurally dissimilar from all others of the multiple projectile components.

BACKGROUND OF THE INVENTION

Projectiles, such as bullets and missiles, may be fired from a variety of delivery devices such as hand guns, rifles, rocket launchers, devices that do not utilize a tubular launch mechanism, and the like. Each projectile will have penetration, fracturing and other characteristics particular to that type and make of projectile. An end user may purchase a projectile based on the penetration, fracturing and other characteristics of the projectiles available for sale. However, the end user is not able to customize projectiles to achieve particular characteristics as may be desired. There is a need, therefore, for a projectile that may be mechanically adapted by an end user so as to achieve desired penetration, fracturing or other characteristics.

SUMMARY OF THE INVENTION

The Mechanically Adaptable Projectile of the present invention can be propelled from a cartridge, shell, or vessel by various means, to include but not limited to, explosion, air, spring, magnetic energy, vacuum, or gravity for the purpose of using the projectile for impacting objects in applications similar to, but not limited to, hunting, law enforcement use of force and tactics, target practice, self defense, firearms training and recreational shooting. The projectile will generally be created in the form and shape of a bullet, missile, or ballistic projectile of many different dimensions to be used in firearms and launching devices of a variety of styles to include, but not limited to, rifled and smooth bore firearms, rail guns, tubes, and devices used for launching or firing projectiles. Using a series of Core Projectile Modules, the manufacturer can customize the projectiles by adding or omitting Interchangeable Components that will alter the size, mass, shape, internal ballistics, external ballistics, terminal ballistics, and mechanical characteristics of the projectile.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an exterior schematic view of a prior art projectile.

FIG. 2 shows an exploded cross section of an embodiment of a mechanically adaptable projectile.

FIG. 3 shows a cross section of an embodiment of a mechanically adaptable projectile.

FIG. 4 shows an exploded cross section of an embodiment of a mechanically adaptable projectile.

FIG. 5 shows an exploded cross section of an embodiment of a mechanically adaptable projectile.

FIG. 6 shows an exploded cross section of an embodiment of a mechanically adaptable projectile.

FIG. 7 shows an exploded cross section of an embodiment of a mechanically adaptable projectile.

FIG. 8 shows an exploded cross section of an embodiment of a mechanically adaptable projectile.

FIG. 9 shows a cross section of an embodiment of a mechanically adaptable projectile.

FIG. 10 shows an exploded cross section of an embodiment of a mechanically adaptable projectile.

FIG. 11 shows an exterior side view of an embodiment of a mechanically adaptable projectile.

FIG. 12 shows a cross sectional side view of the embodiment of FIG. 11.

FIGS. 13-15 show another embodiment of a mechanically adaptable projectile.

FIGS. 16-17 show another embodiment of a mechanically adaptable projectile.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Definitions as used in this description include: Mechanics (Mechanically, Mechanical)—deals with the action of forces on the bodies and with motion, comprised of kinetics, statics, and dynamics; Reactive Qualities—How the projectile reacts when striking a target medium; Mechanical Characteristics—The relationship of the reactive qualities and mechanics; and, Mechanical Design—Visible characteristics of the component.

The present invention is novel in the ammunition and gun related industry by introducing manufacturer and end user adaptability and customization to a range of projectiles that may be used in modern rifles, pistols, guns and other projectile launching devices.

A first embodiment includes a Core Projectile Module of varied mechanical designs and calibers that utilizes materials with a specific gravity no less than that of water and no more than 270 percent greater than that of water; tensile strength properties no less than 6,000 pounds per square inch; compressive strength properties no less than 6,000 pounds per square inch; and a coefficient of friction of no more than 0.5. The Core Projectile Module is capable of being fitted with Interchangeable Components (See FIGS. 2-10, as will be discussed in detail below), or of being used as a projectile in many of its basic unaltered forms. The design of the Core Projectile Module may include varying mechanical designs to facilitate a range of mechanically adaptable options depending on the intended use of the projectile. In one embodiment, the Interchangeable Component may be added or omitted to alter the rate of fracturing. The Core Projectile Module has its own mechanical qualities that may be altered by the Interchangeable Component. Altering the rate of fracture will predictably alter the depth of penetration and propagation of pressure waves upon impact with a given medium, thereby maximizing the intensity of ballistic pressure waves relative to a specified animal target; causing remote cerebral effects as well as remote effects on the spine and internal organs of an animal. This phenomenon is commonly referred to as “hydrostatic shock.” The present invention is specifically designed to embody chosen qualities and characteristics to efficiently deliver a hydraulic reaction and explosive effects on tissue and organs. The Interchangeable Components enable the manufacturer or the end user to customize the round to perform differently according to varying distances, varying weights and varying hide thickness of different animals.

A second embodiment includes a Core Projectile Module of varied mechanical designs and calibers that utilizes materials with a specific gravity no less than that of water and no more than 270 percent greater than that of water, tensile strength properties no less than 6,000 pounds per square inch, compressive strength properties no less than 6,000 pounds per square inch, and a coefficient of friction of no more than 0.5. The Core Projectile Module is capable of being fitted with Interchangeable Components (See FIGS. 2-10), or of being used as a projectile in many of its basic unaltered forms. The design of the Core Projectile Module may include varying mechanical designs to facilitate a range of mechanically adaptable options depending on the intended use of the projectile. The Core Projectile Module is specifically designed to embody chosen qualities and characteristics to propagate energy efficiently enough to induce ballistic shock waves through the target medium, causing the target medium to react violently to the ballistic pressure waves with or without the use of the Interchangeable Components. The unique utilization of the described materials, varied manufacturing and assembly methods, varied velocities, varied sizes, and varied designs of Interchangeable Components enables the creation of a wide variety of projectile design combinations. This novel feature will allow the manufacturer or end user to create a projectile that efficiently and predictably penetrates and propagates energy into specified target mediums. The manufacturer can alter a Core Projectile Module by adding or omitting Interchangeable Components (see FIGS. 2-10) to achieve desired penetration and reactions between the projectile and the intended non-animal target. Among other desirable outcomes, the manufacturer can create a projectile that prevents over penetration of the projectile through an intended target whether animal, vegetable or other materials, thus preventing it from striking unintended animals or things that may be behind the intended target. The qualities of the Core Projectile Module and Interchangeable Components, in their array of configurations, enable the manufacturer or end user to create a projectile that will efficiently fracture when striking a known material, which fracturing causes rapid propagation of pressure waves into the target, causing the materials to react violently to the pressure wave. The projectile pulverizes building materials commonly used in constructing walls in buildings. This may cause significant damage and flying debris within the room beyond the wall. This is a desirable condition in instances of covering fire and suppression fire used by law enforcement and military. It is also desirable that the projectiles used in covering fire be of the type that reduces the incidents of over penetration. Current projectiles used in conventional firearms, in this kind of situation, present a significant risk of over penetrating and striking an unintended subject or object beyond the wall structure.

A third embodiment includes a Core Projectile Module of varied mechanical designs and calibers that utilizes materials with a specific gravity no less than that of water and no more than 270 percent greater than that of water, tensile strength properties no less than 6,000 pounds per square inch, compressive strength properties no less than 6,000 pounds per square inch, and a coefficient of friction no more than 0.5. A Core Projectile Module manufactured from the specified materials will have a bearing surface with a low friction coefficient enabling it to pass down the barrel of a rifle or gun more easily, which lowers heat and pressure within the barrel, enabling higher muzzle velocities and faster external ballistic speed passing through the air, while simultaneously reducing recoil relative to the caliber and mass of the projectile and the powder charge. By reducing the skin friction, these material characteristics enable the projectile to achieve higher flight speeds than previous art made from materials with a higher friction coefficient and an equal ballistic coefficient.

A fourth embodiment includes an Interchangeable Component (See FIGS. 2-10) which may be made from numerous materials including but not limited to copper, brass, aluminum, ceramics and polymers. Interchangeable Components may be designed to interchange with a varying range of calibers and designs of Core Projectile Modules of previously discussed embodiments. The Interchangeable Component may allow the manufacturer or the end user to alter the size, mass, shape, and style of the projectile for the purpose of customizing the internal, external, and/or terminal ballistics of the Mechanically Adaptable Projectile according to the materials or specified medium the projectile will be striking. The Interchangeable Component may be added or omitted to facilitate a predictable rate of fracturing, penetration and propagation of pressure waves upon impact with a specified medium, thereby maximizing the intensity of ballistic pressure waves. The optional Interchangeable Component may alter the mechanical characteristics of a projectile. Altering the rate of fracture may change the propagation of ballistic pressure waves and depth of penetration of the projectile into a specified medium. The ability to alter the reactive characteristics of the projectile may enable the user to customize the rounds for a desired effect on a specified target medium.

In a fifth embodiment, the mechanical characteristics of the projectile are affected by the techniques used in manufacturing, such as utilizing specified materials, pressures and heat to enable different manufacturing techniques. Each unique manufacturing method will be used to predictably alter the mechanical characteristics of the various components comprising a Mechanically Adaptable Projectile, thereby altering the characteristics of the pressure wave that is introduced into the specified target upon impact of the projectile. The methods include, but are not limited to, injection molding, blow molding, rotational molding, extrusion molding, lathe/mill machining, and stamping. The chosen method of manufacturing alters the performance of the projectile in a predictable and marketable manner. This enables a manufacturer to use the same material and change the marketable characteristics of the end product by altering the method of manufacturing and not changing the physical design or type of material. For example, a projectile of identical style, shape and size can have two distinct mechanically functional qualities if one is made through a machine lathe process and another is made by an injection molding process. This manufacturer design flexibility allows adjustment of the number of mechanical characteristics for a projectile of identical size, style and shape.

A sixth embodiment a Core Projectile Module includes varied mechanical designs and calibers that utilizes materials with a specific gravity no less than water and no more than 270 percent greater than that of water, tensile strength properties no less than 6,000 pounds per square inch, compressive strength properties no less than 6,000 pounds per square inch, and a coefficient of friction of no more than 0.5. The unique utilization of the specified range and combination of materials, varied velocities, varied sizes, varied mass and varied mechanical designs of a Core Projectile Module enables the manufacturer to create a projectile that efficiently and predictably propagates ballistic pressure waves into specified targets. The rapid fracturing causes the energy from the projectile to rapidly propagate into the animal being impacted by the projectile. This reduces the depth of wound channels. There is a direct connection to the depth of the wound channel and the amount of traumatic vascular tearing. In other words, the present invention allows the end user to choose components of a projectile so as to provide a desired depth of projectile channel upon impact. Previous art relies on vascular injuries and blood loss to increase their incapacitative capabilities. More vascular tearing requires more significant surgical repairs to prevent blood loss. This present invention allows the manufacturer to create a projectile that relies on ballistic pressure waves and remote cerebral effects from ballistic pressure waves that shock the system into incapacitation, rather than relying solely on vascular injuries and blood loss. By design this projectile will penetrate less and therefore create less vascular tearing associated with a wound channel, thus decreasing the surgical complexity of repairing vascular injuries related to a wound channel. This present invention, therefore, departs from the prior art by changing the mechanism of incapacitation from vascular tearing and trauma, which causes massive bleeding, to relying primarily on ballistic shock waves that cause remote cerebral effects as well as remote effects on the spine and internal organs of an animal. This phenomenon is commonly known as “hydrostatic shock.” Each of the mechanisms of incapacitation has their lethal concerns, but incapacitation by hydrostatic shock may provide more minutes for medical intervention, thereby increasing combat effectiveness while pushing back the margin of lethality.

In a seventh embodiment, the Interchangeable Components can be assembled into or onto, i.e., inserted into or “outserted” onto, a Core Projectile Module using ultrasonic welding. This method of manufacturing is unique to the manufacturing of projectiles. No known prior art utilizes this assembly process to alter the performance of a projectile. Ultrasonic welding of Interchangeable Components to the Core Projectile Module enables press fitting of precision Interchangeable Components of varying materials to the Core Projectile Module, forming a precision projectile such that the projectile will withstand the extreme pressures of gun barrels, rifling, and flight through air, additionally affecting how the specified components react with each other upon impact. The fit tolerance of the Interchangeable Component to the Core Projectile Module alters the mechanical characteristics of the entire projectile by pre-stressing or compressing the Core Projectile Module. As the tolerances change from interference fit to varying press fit tolerances, the interaction of individual components upon each other changes as the mechanical interaction of each component is altered by the tightness of the fit tolerance. The mechanics of fracturing upon impact will change based on the fit tolerances of the Interchangeable Component to the Core Projectile Module. The ballistic pressure waves propagate through the target differently based on changes in the fracturing characteristics of the projectile when impacting a specified target. Also, the varied fit tolerances will alter the reactive qualities of the projectile based on the manner in which impact energy propagates through the projectile upon striking a specified target medium. That in turn alters how the pressure wave propagates from the projectile into the target being impacted by the projectile. This produces desirable and predictable qualities in a projectile that are identifiable and marketable. The use of ultrasonic welding is unusual in the bullet manufacturing industry and is novel and unique to the utility of this art.

In an eighth embodiment, the Interchangeable Component (see FIGS. 2-10) can be fitted inside of the Core Projectile Module, or on the outside of the Core Projectile Module. This enables the Mechanically Adaptable Projectile to be customized to withstand extreme barrel pressures, rifling friction, and extreme velocities as well as preloading stress on the Core Projectile Module. The projectile may also be customized by altering the internal, external and/or terminal structures to change the internal, external, and/or terminal ballistics.

In a ninth embodiment, the interchangeable Component can be added or omitted to the Core Projectile Module to reduce the friction coefficient and mass. This will enable the manufacturing of low recoil cartridges and safe rounds for indoor ranges and other target applications. It will also optimize the projectile's ability to fly through the air for long range shooting (see FIGS. 2-10). The ability to alter the internal, external, and/or terminal structure so as to alter the internal, external and/or terminal ballistics of the Core Projectile Module enables the manufacturer or the end user to customize the projectile to accommodate different shooters or different launching mechanisms.

In a tenth embodiment, the Interchangeable Component can be added to or omitted from the Core Projectile Module (see FIGS. 3, and 9-10) to alter the style of the tip, ogive, base, heal, meplat, or bearing surface of the projectile (see FIG. 3). The Interchangeable Components may include, but are not limited to, various metal tips, polymer tips, varied hollow point tips, boat tails, flat bases, varied bearing surfaces with varying friction coefficients, as well as many other alterations to the basic Core Projectile Module.

In an eleventh embodiment, the Interchangeable Component can be added to the Core Projectile Module to change the length, shape, mass, flight characteristics, rifling twist requirements and specific density of the projectile.

In a twelfth embodiment, the Interchangeable Component can be added to the Core Projectile Module to optimize the projectile to match the barrel twist of a firearm when the projectile is used in such a firearm.

In a thirteenth embodiment the adaptable qualities of a given Mechanically Adaptable Projectile can be changed after the cartridge is fully completed without removing the projectile from the casing.

The Core Projectile Module will now be described in detail. Prior art projectiles (FIG. 1) may include a clad projectile which may have an exterior shape similar to the inventive projectile 10 (FIGS. 2-12). One may note that the inventive projectile 10 may include many similarities in outward appearance to a prior art projectile (FIG. 1). Accordingly, many components of inventive projectile 10 include components having nomenclature similar to the prior art projectile shown in FIG. 1. In particular, prior art projectiles may include a tip 12, bearing surface 14, head or ogive 16, meplat 18, heel 20, base 22, boat or tail 24, cannelure 26 and shoulder 28.

Referring to FIG. 2, inventive projectile 10 may include similarly named surfaces. The example shown in FIG. 2 is one of many amongst the many mechanical designs of projectile or missiles 10 which may be manufactured. Even though the external shape of the inventive projectile 10 may look similar to the external shape of the prior art projectile shown in FIG. 1, in the Mechanically Adaptable Projectile components can be adapted by the manufacturer or the end user to facilitate the adaptation of the internal, external, and/or terminal ballistics of the projectile. In particular, the end user may opt not to alter the Core Projectile Module as manufactured if it already meets the requirements of the end user or the manufacturer. However, the end user or manufacturer may insert an Interchangeable Component into the tip (hollow point) to alter the depth, mass, shape of the tip, or apply an Interchangeable Component to the exterior to alter the diameter friction coefficient of the bearing surface, and/or the length or aerodynamic shape of the projectile. These abilities also enable the manufacturer or the end user to adapt the projectile to the optimal riffling twist and other stabilization features relative to the distance it will need to travel and the medium it will be striking. This enables the projectile's mechanical qualities to be adapted to the needs or intent of the manufacturer or end user, whether the projectile is being used by military or law enforcement to provide covering fire, breaching a door, shooting an animal, target shooting (indoor or outdoor), or by others who may be teaching a new shooter by using reduced recoil rounds in a specific gun until the new shooter learns how the gun functions, or other non military or law enforcement applications.

Prior art projectiles may include toxic materials as their core material, whereas the new Mechanically Adaptable Projectile utilizes a non toxic polymer that reduces complications of soil contamination and risk to pregnant shooters. The low friction coefficient of the Core Projectile Module (FIGS. 2-12) will reduce barrel wear and enable higher velocities compared to old art with a similar ballistic coefficient. The Core Projectile Module example shown in FIG. 2 is one of many potential mechanical designs. This example was lathe turned, but may be manufactured by other means to include, but not limited to, injection molding, blow molding, rotational molding, extrusion molding, hydro forming, and stamping. The method of manufacturing depends on the mechanical characteristics desired.

A Core Projectile Module impact analysis will now be described. When the Core Projectile Module strikes a medium with lower specific gravity than water, the depth of penetration is deeper than in mediums with a specific gravity of water or greater. This is a predictable quality due to the specifications of the material, manner it is manufactured, combination of mechanical qualities and internal, external and/or terminal ballistics. The adaptability of the inventive projectile enables the changing or adding of Interchangeable Components to the Core Projectile Module by the end user or manufacturer for the purpose of adapting the mechanical qualities, thus altering the propagation of ballistic pressure waves, such as by altering the Core Projectile Module by adding Interchangeable Components with varying specific gravities, friction coefficients and shapes.

For example, when viewing a hole in a material, such as a piece of wood, through which a projectile has traveled, the shape of the hole may indicate that there is a slight projectile instability with the rifle used. The inventive projectile could be used with such a rifle and fitted with an Interchangeable Component that alters the overall specific gravity of the projectile thereby causing stabilized rotation of the projectile fired from that particular rifle. In this manner, the user of the particular rifle could adapt the projectiles fired from his rifle to provide a more stable projectile travel path from the rifle.

In another example of use, a material, such as a piece of wood, may show splitting on the backside of the board around the projectile path of the inventive projectile. The board may be split in a conical pattern outward from the centerline of the projectile path. At the center of the pressure pattern there may be more crushing of the wood material as the pressure wave propagates through the wood. The depth of the damage along the centerline of the projectile's path may be deeper and grows shallower as the pressure wave propagates outward from the centerline. This demonstrates how the building material violently reacted to the ballistic pressure wave which results in crushing and fragmenting of the material from the inventive projectile. A typical projectile path of the inventive projectile through a medium will show a widening damage path as the ballistic pressure wave propagates through the wood.

The Specific Gravity, Projectile Fracturing, and Ballistic Pressure Wave Propagation properties will now be described.

When a ballistic pressure wave impacts an object with a specific gravity nearly equal to that of water, the crushed particles from the medium will ride on the pressure wave as it blows back toward the direction from which the projectile originated. In one test conducted on the inventive projectile, the remaining particles from a Core Projectile Module that was fired into a wood medium were examined. The original Core Projectile Module weighed 151 grains (0.345 ounces). The recovered fragments from the Core Projectile Module weighed 11 grains (0.025 ounces). Such an efficient fracturing and crushing of the Core Projectile Module enables efficient propagation of ballistic pressure waves through the medium.

In one embodiment including a Core Projectile Module with the addition of an Interchangeable Component, the Interchangeable Component is designed to delay the fragmentation of the Core Projectile Module, allowing the projectile to enter the medium more deeply before fragmenting and propagating the ballistic pressure wave into the medium. The Interchangeable Component is altering the mass, tip, meplat, ogive, ballistic coefficient and overall length of the projectile. All of these changes combine to alter the mechanical characteristics, and internal, external and/or terminal ballistics of the projectile when it impacts varying mediums. The end user or the manufacture is able to adapt the projectile to optimize specific qualities depending on the use of the projectile.

Additionally, in this particular embodiment, the components in this particular projectile are lathe turned from Delrin® 150E and 6061 T6 aluminum. This provides for known ductility of the material components, thereby creating a predictable, marketable quality. Annealing one or both of the components will alter the ductility of the components. This can be done before assembling or as an assembled projectile. Changing the ductility of one or both of the components provides a change in fracturing characteristics, which in turn provides a predictable performance change in the Mechanically Adaptable Projectile. Also, the predictable performance of this exact configuration can be altered by changing the method of manufacture, thereby increasing the applications of a single mechanical design by the number of alternate manufacturing methods.

In an embodiment where the projectile is machine lathed instead of utilizing injection molding and investment casting, the fit tolerances of the Interchangeable Component (such as 6000 series T6 aluminum with a sharp point and small meplat) can be altered from interference fit to varying degrees of press fit. By increasing the tightness of the fit, the manufacturer can preload stress on the Core Projectile Module. This will reduce the amount impact needed to cause the Core Projectile Module to fracture, thereby reducing the amount of velocity needed to cause the necessary fracturing for efficient release of ballistic pressure waves into the target object. This in turn enables the use of the projectile in low recoil scenarios and low efficiency barrels. Thus, the inventive projectile enables the use of an identical mechanical design in a greater array of applications while maximizing efficiency. The use of an Ultrasonic Welder will enable the manufacturer to maximize the limits the projectile can be pre-stressed for this application.

FIG. 2 shows that insertion of an Interchangeable Component 30 into the Core Projectile Module 32 reduces the size of the hollow point 34 and, depending on material changes mass and depending on fit tolerance, can be used to preload stress on the projectile 10 to alter reactive qualities upon impact. It will also increase the size of the meplat 18 without altering the length of the projectile. Inserting and interchangeable component 30 into the tip of the Core Projectile Module 32 changes the shape and/or size of tip 12, ogive 16 and meplat 18.

FIG. 3 shows a Core Projectile Module 32 having an interior cavity 36 for receiving an interchangeable component 30, such as a hollow point 34 (FIG. 2), whereas cavity 36 has a smaller diameter 40 than a cavity 38 of component 32 of FIG. 2.

FIG. 4 shows insertion of an Interchangeable Component 30 into the base 22 of the Core Projectile Module 32. Changing the base 22, shoulder 28, length 42 (FIG. 1) and mass of projectile 10. Depending on the fit tolerance, this insertion method of component 30 can preload stress on a portion of the projectile to alter its reactive qualities upon impact.

FIG. 5 shows insertion of an Interchangeable Component 30 to alter the tip 12 so that it is pointed, thereby altering the size of the meplat 18 and the ogive 16 of projectile 10. This Interchangeable Component 30 can be made of a material that alters the mass of the projectile. It can also have a fit tolerance that preloads stress by pressing outward on the projectile; thereby changing the reactive qualities of the projectile upon impact.

FIG. 6 shows that insertion of an Interchangeable Component 30 into the Core Projectile Module 32 reduces the size of the hollow point 34 and, depending on material, changes mass and depending on fit tolerance, can be used to preload stress on the projectile 10 to alter reactive qualities upon impact. It will also increase the size of the meplat 18 without altering the length of the projectile.

FIG. 7 shows that insertion of an Interchangeable Component 30 into the Core Projectile Module 32 may increase the size of the hollow point 34 and, depending on material changes mass and fit tolerance, can be used to preload stress on the projectile 10 to alter reactive qualities upon impact. It will also increase the size of the meplat 18 without altering the length of the projectile.

FIG. 8 shows that insertion of an Interchangeable Component 30 into the Core Projectile Module 32 may increase the size of the tip 12 while reducing or eliminating the hollow point and, depending on material, changes mass and fit tolerance, can be used to preload stress on the projectile 10 to alter reactive qualities upon impact. It will also increase the size of the meplat 18 without altering the length of the projectile.

FIG. 9 shows an Interchangeable Component 30 being fitted to the outside of the Core Projectile Module 32. The Interchangeable Component 30 may be sized to have an external diameter 44 greater than, equal to, or less than the external diameter 46 of the Core Projectile Module 32.

FIG. 10 shows an exploded view of an Interchangeable Component 30 being fitted to the outside of the Core Projectile Module 32. The Interchangeable Component 30 may be fitted to the Core Projectile Module 32 by any means, such as press fit, adhesive, or welding, for example.

FIG. 11 shows an exterior side view of an Interchangeable Component 30 fitted within a Core Projectile Module 32. The Core Projectile Module 32 may be fired without an interchangeable component 30 being placed therein. In such a case the component 32 is referred to as a hollow point projectile. In the embodiment shown, component 32 includes a tapered base 22, a bearing surface 14, a tapered head ogive surface 16 a and a flat front surface 50 a positioned perpendicular to an elongate axis 48 of the projectile. Accordingly, in cases where component 32 is fired without an interchangeable core 30 positioned therein, component 32 will include a tapered ogive surface 16 at the front of the projectile 10 during flight. In one embodiment, component 32 is manufactured of a plastic material, such as Acetal, and interchangeable component 30 is manufactured of metal, such as copper. Interchangeable component 30 includes a tapered head ogive surface 16 b and a flat front surface 50 b positioned perpendicular to elongate axis 48 of the projectile.

A variety of interchangeable components 30 may be placed within component 32 by the end user at the site of discharge of projectile 10, such as at a shooting range, at a law enforcement live operations site, in a hunting setting, or any other location where the projectile 10 may be discharged. Accordingly, the end user of the projectile may alter the characteristics of the projectile in real time, to suit their needs for a particular, live situation in which the end user, i.e., the shooter of the projectile, may find themselves.

FIG. 12 shows a side cross sectional view of projectile 10 of FIG. 11, wherein interchangeable component 30 includes a head ogive 16 b such that when component 30 is placed within component 32, the ogive surface 16 a of component 32 and ogive surface 16 b of component 30 together form a continuous surface 16 that together define the same angle with respect to an elongate axis 48 of the projectile 10. In other words, surface 16 a and 16 b together define ogive surface 16 of projectile 10, including both components 30 and 32.

Still referring to FIG. 12, in this embodiment component 32 includes a cavity 36 having an inner diameter 40 that is larger than an outer diameter 52 of an extension 54 of component 30 that extends into cavity 36. In one particular embodiment, inner diameter 40 may be 0.28 inches and outer diameter 52 may be 0.26 inches. Accordingly, extension 54 of component 30 is loosely received within cavity 36. During firing of projectile 10 in a forward direction 56, meplat surface 18 of component 30 is supported on front surface 50 a of component 32 to retain component 30 within component 32. During times of non-use, i.e., when projectile 10 is resting on a table for example, component 30 is easily manually removed from component 32 by a user with their bare hands, without the need for use of specialized removal tools. If the projectile is tipped upside down for example, with front surface 50 b of component 30 facing downward toward the ground, when component 32 is held steady, the force of gravity will pull component 30 from its loose-fitting position within component 32. Accordingly, component 30 is held loosely within cavity 36 of component 32. In this embodiment, the inner diameter 40 of cavity, which is larger than the size of outer diameter 52 of extension 54 of component 30, ensures that component 30 is not mechanically or frictionally fixedly retained within component 32. Instead, component 30 is retained within component 32 by the contact of meplat surface 18 of component 30 contacting front surface 50 a of component 32 during a force upon projectile in a direction opposite to forward direction 56, such as during firing of projectile 10 in forward direction 56, or when projectile 10 is sitting at rest with front surface 50 b of component 30 extending upwardly such that the force of gravity retains surface 18 of component 30 on front surface 50 b of component 32. In other words, tipping projectile 10 upside down will result in component 30 slipping from component 32 to separate the two components. This loose fitting allows different components 30 to be interchangeably placed with ease within component 32 by an end user. Accordingly, the projectile set of the present invention, including a component 32 and multiple interchangeable components 30, each including differing characteristics (such as a different mass or shape to allow altering of the penetration or fracturing of the projectile upon on impact, for example), allows both the manufacturer and the end user to keep a lower inventory of projectile parts on hand while still allowing for multiple projectiles to be formed for sale or use. For example, a manufacturer may keep one standard component 32 in stock, along with multiple different interchangeable components 30 in stock, thereby allowing the manufacturer to deliver multiple different types of projectiles to end users, without requiring the manufacturer to retain multiple different completed projectiles on hand. This may reduce the inventory space needed by the manufacturer because the interchangeable components 30 maybe much smaller in size than a fully formed projectile 10. Similarly, an end user may purchase several components 32 and several different types of interchangeable components 30 which may allow the end user to customize their projectile 10 on site, without requiring many different types of projectiles to be stored or carrier by the end user. In law enforcement live shooter applications, the inventive projectile may allow an officer to carry a standard component 32 and multiple interchangeable components 30 on their person, such that the law enforcement officer may be able to customize a projectile during live situations. In one particular example, an officer confronted with a live shooter positioned within a duplex, will be able to customize a projectile that when encountering sheet rock, the projectile will explode the sheet rock without penetrating through the sheetrock, so that innocent parties positioned on the other side of the sheet rock wall from the live shooter, such as in the other side of the duplex, will be unharmed and unaffected by actions taken to disable the live shooter. Accordingly, the projectile of the present invention allows officers in the field, during live law enforcement actions, to make instantaneous decisions about the desired penetration depth and fracturing characteristics of projectiles they wish to use and to create such customized projectiles on site. Such ease of changing out a component, on site and in live shooting situations, has heretofore not been provided.

In another embodiment, which takes into account Newton's Cradle Effect, the projectile includes a threadably attachable and detachable interchangeable component (FIGS. 15 and 16) to facilitate adaptability in a “live shooter application” scenario described herein.

In contrast, the loose fitting interchangeable components may be utilized in scenarios where it is not desirable for the core projectile module and the interchangeable component to remain intact as a single projectile. In one loose fitting embodiment the projectile utilizes spherical interchangeable components that are loosely fitted. Due to Newton's Cradle Effect the spherical interchangeable components separate from the core projectile module during flight and fly directly in front of the Core Projectile Module and will strike an intermediate obstacle, such as glass, just before the Core Projectile Module. The loose fitting Interchangeable Components will shatter the glass directly in front of the Core Projectile Module. This will allow the Core Projectile Module to pass through the intermediate obstacle (glass) and strike a target behind the glass. During testing, it has been observed that when this embodiment of the Core Projectile Module strikes the target, it will function as if there is no Interchangeable Component. In one embodiment the loose fitting Interchangeable Components may be affixed to the Core Projectile Module during manufacturing assembly of the cartridge, and not in the field. In this embodiment the assembly technique holds the loose fitting Interchangeable Components in place during transport and loading. In particular, a clear plastic disc is fitted just over the top of the Core Projectile Module and under the roll crimp of the shell hull. Porcelain may be the best material for this application. Steel has also been utilized.

The projectiles that are adaptable in the field during live police and military events may use threadably attachable/detachable Interchangeable Components. Some of the threaded interchangeable components do not require tools for insertion (FIG. 16). Socket heads may be used on components when it is desirable to include a hollow point on the projectile (FIG. 16). The hex key socket shown may double as a hollow point and a feature for engaging a tool (FIG. 16). Some insertable components have tapered ends allowing digital grasping for threadable manipulation of the Interchangeable Component (FIG. 16).

In one embodiment, projectile component 32 of the present invention may be manufactured of a synthetic material, such as Quadrant EPP Acetron® POM-H Homopolymer Acetal. This polymer has a specific gravity of 1.41 g/cc, water absorption of 0.20%, water absorption at saturation of 0.90%, hardness of 89 (Rockwell M), hardness of 122 (Rockwell R), tensile strength of 11,000 psi, tensile strength at 65 Degrees of 7,200 psi, elongation at break of 30%, tensile modulus of 450 ksi, flexural strength of 13,000 psi, flexural modulus of 450 ksi, compressive strength of 16,000 psi, compressive modular of 450 ksi, shear strength of 9,000 psi, izod impact, notched of 1.00 ft-lb/in, coefficient of friction, dynamic of 0.25, K (wear) factor of 200×10exp(−10)inch exp(3)/ft-lb-hr, and limiting pressure velocity of 2,700 psi-ft/min, surface resistivity of 1.00exp(13) ohm, dielectric constant of 3.7 at frequency of 1exp(6) Hz, dielectric strength of 450 kV/in, and a dissipation factor of 0.0050 at frequency of 1exp(6) Hz. These properties of the polymer result in no or very limited turbulence at the back end of the projectile during flight, substantially increasing the speed of inventive projectile 10 during flight. In sample tests of a 12 gauge inventive projectile 10, the projectile was recorded during flight at speeds of over 4,000 feet per second, where as prior art projectiles typically have a maximum speed of 1,200 to 1500 feet per second. The increased speed of inventive projectile 10 is believed to be due to the decreased weight of component 32 manufactured of polymer compared to prior art shells manufactured of metal, and due to the very low air resistance created by inventive projectile 10 due to component 32 being manufactured of polymer materials. In other words, the outer surface 58 of projectile 10 has an extremely smooth low skin friction, compared to the outer surface of prior art metal projectiles, thereby resulting in the extremely fast speeds of projectile 10.

In one embodiment, one of interchangeable components 30 may be manufactured of yellow brass, C27450, having a chemical composition of 60.0 to 65.0 Cu, 0.35 Fe, 0.25 Pb, and the remainder being Zn, with a nominal range of Cu being 62.5 and Zn being 37.5. In another embodiment, one of interchangeable components 30 may be manufactured of Phosphorus deoxidized tellurium bearing Copper, UNS C14500, OSO15 Temper. Use of the yellow brass or Copper alloy will provide an interchangeable component 30 have the mass and other properties that may be desirable to achieve particular ballistics characteristics.

FIGS. 13-15 show another embodiment of a mechanically adaptable projectile component manufactured of Acetron POM-H Homopolymer Acetel, with an unfilled central cavity.

FIG. 13 shows an isometric view of a component 32.

FIG. 14 shows a side view of the component of FIG. 13 wherein component 32, in this embodiment, defines a length 60 of 1.0 inches, a base 22 width 62 of 0.5 inches, boat tail 24 width 64 of 0.115 inches (measured perpendicular to elongate axis 48), a boat tail 24 length 66 of 0.15 inches (measured parallel to elongate axis 48), a bearing surface 14 length of 68 of 0.5 inches, a head ogive 16 length 70 of 0.350 inches (measured parallel to axis 48), a head ogive 16 width 72 of 0.225 inches (measured perpendicular to axis 48), and a diameter 40 of cavity 36 of 0.280 inches.

FIG. 15 shows an end view of component 32 having a diameter 74 of 0.730 inches, and an end mill 76 of ¾ inches, 0.250-2UNC-2A, ⅝ inches. These are the specifications of threads 94 on the interior of threaded bore, or cavity 36, of FIGS. 14 and 15 (only a few threads 94 are shown on the interior of module 32 in the side view in FIG. 14 for ease of illustration). Threads 96 (only a few threads 96 are shown on the exterior of insert 30 shown in FIGS. 16 and 17 for ease of illustration) on threaded exterior surface 98 of insert 30 can be threadably attached and detached from the threads 94 of bore 36 of the Core Projectile Module 32, shown in FIGS. 14 and 15. Mating threads 94 and 96 secure the insert 30 to the projectile body 32. This is the preferred embodiment for adapting the projectiles in the field during live police action, such as described above in the section detailing where a live shooter may be hiding in one side of a duplex, with innocent bystanders positioned in the other side of the duplex.

FIGS. 16-17 show another embodiment of a mechanically adaptable projectile component.

FIG. 16 is a side view of an interchangeable component 30 manufactured of phosphorus deoxidized tellurium copper. Component 30 has a length 80 of 0.75 inches, a nose 12 length 82 of 0.125 inches (measured parallel to axis 48), a nose 12 width 84 of 0.050 inches, a nose 12 tip width 86 of 0.150 inches, and a diameter 88 of 0.250 inches. Nose tip 12 facilitates ease of assembly in the field. The taper of the nose portion 12 is intended to make it easier to start the threadably attachable Interchangeable Component 30 into cavity 36 of component 32 in a situation where a user would want a hollow point projectile. If the insert 30 is reversed, and the socket end portion of component 30 is first placed into cavity 36 of component 32, the user may utilize the tapered nose feature 12 to grasp for threadable attachment without a tool. The tapered nose section 12 can become a portion of the ogive or screwed in so it becomes a feature of the hollow point. This gives this single Interchangeable Component 30 at least three variations of use.

FIG. 17 is an isometric back view of component 30 of FIG. 16 including a cavity 90 having a width 92 of 0.250 inches, so as to define a 5/32 inches Allen key socket. In this embodiment, component 30 is positioned in a cavity in the rearward surface of a component 32 by use of an Allen key wrench. The Allen socket cavity may be utilized as a mechanism for pulating the part with an Allen key and as a smaller hollow point cavity projectile 10.

Water has a specific gravity of 1 and we have learned that creating projectiles and interchangeable components from materials with known mechanical properties including their specific gravity enables us to predict how the projectiles will interact with water. We are using water as the preferred medium because the properties of water are not typically susceptible to human error, or organic variability upon creation. With water as the primary “known” we are able to predict how a material will react when hitting a water based medium. This provides an experimental starting point wherein we evaluate how the addition of other variables will alter how a projectile of a known specific gravity will react to water. For example, using a Core Projectile Module with known specific gravity (SG) and other mechanical properties and observe how the projectile interacts with water. When this reaction becomes known then the Core Projectile Module becomes the universal component on which Mechanically Adaptable Projectile can be created.

Then we establish a linear model wherein we juxtapose a specific projectile performance along the linear scale to predict how that projectile will react when striking other mediums wherein the reaction is known as it relates to water. The linear scale would place water at the center of the scale with an SG of 1 and list potential mediums along the scale in both ascending and descending order according to their known SG. A scale could potentially place the SG of air on the lowest end of descending knowns and steel on the highest end of the ascending knowns.

There is a large body of study involving the use of water as a base medium for examining ballistics. Courtney et al have done many studies wherein they examine ballistic pressure waves in water. Courtney et al have taken what they learned and have examined other experiments in light of what they have learned from their studies and they have been able to answer questions about ballistic science that were previously unsettled science. They have intensely studied an entire body of ballistic science involving remote wounding. They have settled numerous beliefs and resolved questions of predecessors in the science. We have used their work and the work of their predecessors and partners to provide a basis of knowledge that has enabled us to develop the scientific principles espoused in the Mechanically Adaptable Projectile science, described herein.

The bodies of various animals are largely water based. The SG of building materials have a range of density (SG) that is greater than water (1.0) and also less than water. This is the basis from which mechanically adaptable projectile components are created. This is the basis of knowledge through which component interchangeability and interactivity is determined.

Through scientific study, a specific core projectile module of a specific design can be used to impact water. Through observation, the reactivity of the component is known and then a pattern of predictable reactivity is discovered by observing the difference in reaction when impacting the same core projectile module to other known mediums. Then that known reactivity is further examined by adding an interchangeable component to the known core projectile module and observing how the interchangeable component alters the previously known reactivity of the core projectile module. In the above process water becomes the central and preferred known upon which predictable reactivity is built.

In the above description numerous details have been set forth in order to provide a more through understanding of the present invention. It will be obvious, however, to one skilled in the art that the present invention may be practiced using other equivalent designs. 

I claim:
 1. A method of manufacturing a projectile, comprising: providing a projectile body, said body including an aperture adapted to receive therein one of multiple projectile components; inserting a projectile component into said aperture of said projectile body; and releasably securing said component to said body.
 2. The method of claim 1 wherein said releasably securing said component to said body comprises securing said component with mating threads.
 3. The method of claim 1 wherein said projectile component has first and second ends positioned opposite one another and wherein said first and second ends of said projectile component are each adapted to be a leading edge of said projectile component when inserted into said projectile body.
 4. The method of claim 1 wherein said releasably securing said component to said body comprises securing said component to said body by the force of gravity.
 5. The method of claim 1 wherein said inserting said projectile component into said aperture is conducted manually.
 6. The method of claim 1 wherein said providing a projectile body comprises molding a body from a polymer.
 7. The method of claim 1 wherein said projectile component is manufactured of a metal.
 8. The method of claim 1 wherein said securing said component to said body is conducted by an end user at a time of use of said projectile.
 9. The method of claim 1 wherein said projectile body includes an exterior bearing surface and a base region and wherein said projectile component includes a tip and defines a meplat.
 10. A method of constructing a projectile: providing a projectile body that includes an interior cavity; providing a plurality of unique projectile components, each unique projectile component sized to be received at least partially within said interior cavity of said projectile body; and manually placing one of said plurality of unique projectile components at least partially into said interior cavity of said projectile body so as to form a projectile.
 11. The method of claim 10 wherein said projectile body is manufactured of a polymer.
 12. The method of claim 10 wherein at least one of said plurality of unique projectile components is manufactured of a metal.
 13. The method of claim 10 wherein said step of placing one of said plurality of unique projectile components at least partially into said interior cavity of said projectile body is conducted by an end user immediately prior to discharging said projectile from a projectile launcher. 